Low-cost fully additively manufactured passive microwave components exploiting available 3D flexibility

This paper presents a novel technique for low-cost realization of fully additively manufactured passive microwave components through Stereolithography and selective metallization. The introduction of the third dimension (Z-axis) allows to improve parameters of the circuits (impedance match, isolation, etc.) by realization of variable thickness air layers underneath the circuits’ patterns, which additionally lower the overall circuit losses caused by 3D printing material dielectric properties. Realization of a directional coupler, a low-pass filter, and a patch antenna utilizing the proposed manufacturing technique is discussed in detail and experimentally validated. The obtained measurement results for circuit demonstrators operating within the centimeter frequency range prove the benefits and performance of the introduced technique.